Smurfit Kappa, Paper Mill Basin, Snodland.

Project Background and Objectives

The Paper Mill Basin at Smurfit Kappa’s Snodland facility forms a critical part of the site’s operational water infrastructure, supporting industrial processes and water management within a live manufacturing environment. Sections of the existing basin walls had deteriorated over time, resulting in a requirement to structurally reinforce the lagoon perimeter to ensure long-term integrity, operational resilience, and safety.

The overarching objective of the project was to construct new permanent retaining structures along the north and south sides of the basin, forming narrow reinforced caissons capable of withstanding hydraulic and ground pressures while interfacing with existing assets. Given the constrained working environment, proximity to live operations, and the requirement to work predominantly over water, the scheme demanded careful planning, specialist plant, and a robust safety-led delivery strategy.

SPI Piling Ltd was appointed by Breheny Civil Engineering to deliver the specialist sheet piling and tie rod package, forming a key enabling workstream within the wider basin remediation scheme.

Project Scope and SPI Involvement

SPI’s scope comprised the design-informed installation of twin permanent steel sheet pile walls and an associated waling and tie rod system, forming reinforced caissons along both sides of the basin.

Key elements of SPI’s scope included:

• Installation of over 200 permanent GU23N steel sheet piles, predominantly 12.0m in length, with closure piles and corner details.
• Formation of north and south basin walls, including land-side and water-side pile lines.
• Installation of fabricated twin PFC waling beams, secured to the sheet piles using anchor bolts.
• Installation and stressing of high-capacity Macalloy tie rods at regular centres to complete the caisson system.
• Working from a large modular floating pontoon, supported by attendant cranes and safety boats.
• Use of Movax side-grip piling technology, supplemented by impact driving where required.
• Close coordination with Breheny’s site team to maintain access, sequencing, and safety within a live industrial environment.

SPI was responsible for delivering this technically complex package safely, accurately, and in full compliance with the project specification and programme constraints.

Methodology and Execution

Installation Approach

Due to restricted access and the requirement to work over water, SPI adopted a floating plant methodology. A modular Linkflote pontoon was assembled within the basin to provide a stable working platform for the piling operations. Stability calculations, controlled deck loading, and continuous monitoring ensured the pontoon remained compliant throughout the works.

Sheet piles were installed primarily using a 35-tonne excavator-mounted Movax side-grip hammer, allowing precise handling, pitching, and driving of piles. This approach significantly reduced working footprint, improved accuracy, and minimised disruption to adjacent structures.

Where ground conditions prevented piles from achieving design toe levels under vibration alone, impact driving using a BSP DX25 hammer was employed in a controlled manner, with pile head preparation and driving records maintained throughout.

Tie Rod and Waling Installation

Following completion of the sheet pile walls, SPI installed the permanent waling and tie rod system. Fabricated twin PFC walings were positioned and fixed to the piles, with high-strength tie rods threaded through the caissons and secured using anchor bolts and bearing plates.

Access for these works was achieved using a combination of lightweight access pontoons, MEWPs, and temporary staging, enabling safe installation while maintaining segregation from live water and plant movements.

Safety, Quality & Risk Management

Safety was central to SPI’s delivery strategy on this project. All activities were planned and executed in accordance with SPI’s Integrated Management System and Breheny’s Principal Contractor requirements.

Key safety and quality controls included:

• Detailed task-specific RAMS and lift plans, briefed to all operatives prior to works commencing.
• Comprehensive working over water controls, including mandatory lifejackets, rescue boats, and man-overboard procedures.
• Strict control of lifting operations, with CPCS-qualified operators, appointed persons, and exclusion zones in place.
• Regular inspection and certification of all plant, lifting equipment, and floating platforms.
• Environmental controls addressing fuel management, spill prevention, noise, and vibration.
• Continuous pile verticality checks, driving records, and installation logs to ensure compliance with design tolerances.

This structured and disciplined approach ensured the works were delivered with no reportable incidents and to the required quality standards.

Challenges & Adaptive Collaboration

The project presented several technical and logistical challenges:

• Working within a live industrial basin, requiring careful coordination to avoid disruption to ongoing site operations.
• Over-water construction, necessitating robust floating plant controls and emergency preparedness.
• Tight spatial constraints, particularly when installing twin pile walls and tie rods within narrow caisson widths.
• Variable ground conditions requiring flexibility between vibratory and impact piling methods.

SPI addressed these challenges through proactive collaboration with Breheny Civil Engineering, adapting methodologies where required and sequencing works to maintain progress without compromising safety or quality. Regular coordination meetings and site-based decision-making ensured risks were managed effectively and delays avoided.

Outcomes & Value Delivered

SPI successfully delivered the full piling and tie rod package in line with programme and specification, achieving:

• Installation of over 200 permanent sheet piles forming reinforced basin walls.
• Safe and efficient delivery using Movax side-grip technology from a floating platform.
• High-quality integration of walings, anchors, and tie rods to form a durable permanent solution.
• Minimal disruption to the client’s live operational environment.

The works now provide Smurfit Kappa with a robust, long-term structural solution, safeguarding the basin and supporting continued site operations.

Lessons Learned & Strategic Strengths

This project reinforced several key strengths within SPI’s delivery capability:

• Specialist over-water piling expertise, including floating plant operations and complex logistics.
• Flexible methodology, enabling rapid adaptation to ground conditions and site constraints.
• Strong safety culture, particularly in high-risk environments involving lifting and water interfaces.
• Collaborative working, ensuring seamless integration with the Principal Contractor and wider project team.

These strengths position SPI as a reliable partner for complex industrial, marine, and water-retaining structure projects.

Summary

The Paper Mill Basin project at Snodland demonstrates SPI Piling Ltd’s ability to deliver technically demanding sheet piling solutions in constrained, high-risk environments. By combining specialist plant, experienced personnel, and a safety-led approach, SPI successfully installed permanent retaining structures that meet the client’s long-term operational and structural requirements.

The project highlights SPI’s capability to work collaboratively within live industrial sites, manage complex over-water operations, and deliver high-quality outcomes safely and efficiently. This experience underlines SPI’s suitability for future basin, quay, lagoon, and water infrastructure schemes across the UK.